differential FORD MUSTANG 2003 Repair Manual

REMOVAL AND INSTALLATION
Axle Assembly
Removal and Installation
1. CAUTION: The vehicle must be on level ground and at curb height.
Mark the rear shock absorbers relative to their protective sleeve. zDuring installation, raise the suspension to this reference mark before tightening the
suspension fasteners.
2. Raise and support the vehicle. For additional information, refer to Section 100 - 02 .
3. Remove the rear wheel and tire assemblies. For additional information, refer to Section 204 - 04 .
4. CAUTION: Index- mark the driveshaft flange and pinion flange (4851) to maintain
initial balance during installation.
CAUTION: The driveshaft centering socket yoke fits tightly on the pinion flange
pilot. Never hammer on the driveshaft or any of its components to disconnect the yoke
from the flange. Pry only in the area shown, with a suitable tool, to disconnect the yoke
from the flange.
Disconnect and position the driveshaft out of the way. For additional information, refer to
Section 205 - 01 .
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Klj . 1 ba
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5.
NOTE: If necessary, use Rust Penetrant and Inhibitor F2AZ-19A501- A meeting Ford
specification ESR-M99C56- A to loosen the sensor for removal.
Remove the rear anti- lock brake sensors from the rear disc brake adapters. For additional
information, refer to Section 206 - 09A .
6. CAUTION: Index- mark the brake discs and the wheel studs prior to brake disc
removal.
CAUTION: Do not allow the calipers to hang from the brake hoses.
Remove the rear brake discs. For additional information, refer to Section 206 - 04 .
7. CAUTION: Secure the differential housing (4010) to the jack with a suitable strap.
Support the differential housing with a suitable hi- lift jack. Klj . 2 ba
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8. Remove and discard the nuts and bolts retaining the shock absorbers to the axle.
9. Remove and discard the nuts and bolts retaining the upper suspension arm and bushings to the
differential housing.
10. Lower the axle slightly, and remove the springs.
11. Remove and discard the nuts and bolts retaining the lower suspension arm and bushings to the axle. Klj . 3 ba
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DISASSEMBLY AND ASSEMBLY
Differential Case and Ring Gear
Disassembly
1. Remove the differential assembly from the differential housing. For additional information, refer to Differential Case in this section.
2. Remove the bolts.
3. CAUTION: Do not damage the threads in the bolt holes.
Insert a punch in the bolt holes and drive off the ring gear.
SECTION 205-
02A: Rear Drive Axle/Differential — Ford 7.5-Inch Ring
Gear 2003 Mustang Workshop
Manual Special Tool(s)
2-
Jaw Puller
205- D072 (D97L-4221- A) or
equivalent Installer, Differential Side
Bearing
205-
009 (T57L-4221- A1) Step Plate
205-
D016 (D80L-630- 5) or
equivalent Klj . 1 ba
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4. Using the special tools, remove the differential bearings (4221), if necessary.
5. Remove the bolt.
6. Remove the differential pinion shaft (4211).
7. Rotate and remove the differential pinion gears (4215) and differential pinion thrust washers
(4230). Klj . 2 ba
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8. Remove the differential side gears (4236) and the differential side gear thrust washers (4228).
Assembly 1. Lubricate the differential side gear thrust washers and the differential side gear journals, and assemble the washers to the gears.
zUse SAE 80W- 90 Premium Rear Axle Lubricant XY-80W90- QL or equivalent meeting
Ford specification WSP- M2C197-A.
2. Lubricate the differential pinion thrust washers and the differential pinion gears, and assemble the washers to the gears.
zUse SAE 80W- 90 Premium Rear Axle Lubricant XY-80W90- QL or equivalent meeting
Ford specification WSP- M2C197-A. Klj . 3 ba
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3. Position the differential side gear and thrust washer assemblies in the differential case.
4. Engage the differential pinion gears with the differential side gears and rotate the pinion gears
to align with the differential pinion shaft bore.
5. Insert the differential pinion shaft. zAlign the hole in the differential pinion shaft with the hole in the differential case.
6. NOTE: If a new bolt is unavailable, coat the original bolt threads with Threadlock and Sealer
EOAZ- 19554- AA or equivalent meeting Ford specifications WSK-M2G351- A5 prior to Klj . 4 ba
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installation.
Install a new bolt finger-
tight.
7. Using the special tool, install the new differential bearings, if removed.
8. Position the ring gear and the differential case. Align the bolt holes by starting two bolts through the holes in the differential case and the ring gear. Press the ring gear on the differential case.
9. Install the bolts. zApply Stud and Bearing Mount EOAZ-19554- BA or equivalent meeting Ford specification
WSK- M2G349- A1 to the bolt threads. Klj . 5 ba
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10. Install the differential case. For additional information, refer to
Differential Case in this section. Klj . 6 ba
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SPECIFICATIONS
a
If it is necessary to refill a Traction- Lok® axle with new lubricant, add 118 ml (4 oz) of Additive
Friction Modifier C8AZ-19B546-A or equivalent meeting Ford specification EST- M2C118-A before
filling the axle with the new lubricant.
b In- vehicle repair refill capacities are determined by filling the rear axle with the specified lubricant to
6.4- 14.3- mm (1/4- 9/16-in) below the bottom of the fill hole.
SECTION 205-
02B: Rear Drive Axle/Differential — Ford 8.8-Inch Ring
Gear 2003 Mustang Workshop
Manual General Specifications
Item Specification
Lubes and Sealers
SAE 75W-
140 High Performance Rear Axle
Lubricant
F1TZ- 19580- B WSL-
M2C192- A Premium Long-
Life Grease XG -1-C ESA-
M1C75- B Rust Penetrant and Inhibitor F2AZ-19A501-
A ESR-
M99C56- A High Temperature Nickel Anti-
Sieze Lubricant
F6AZ- 9L494- AA ESE-
M124A- A Additive Friction Modifier C8AZ-
19B546-A EST-
M2C118- A Clear Silicone Rubber D6AZ-
19562-AA ESB-
M4G92- A Threadlock and Sealer EOAZ-19554-
AA WSK-
M2G351- A5 Lubricant Fill Level Checks
Additive Friction Modifier 118 ml (4 oz)
Approximate axle fill capacity
a b 1.66-1.77-
liters (3.5-3.75-pints)
6.4-14.3- mm (1/4-9/16- in) below the bottom of
the fill hole Clearance, Tolerance and Adjustments
Maximum ring gear back face runout 0.102 mm (0.004 in)
Maximum differential case runout 0.076 mm (0.003 in)
Differential side gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Differential pinion gear thrust washer thickness 0.762 mm -
0.813 mm (0.030 in - 0.032 in) Maximum axle shaft end play 0.762 mm (0.030 in)
Ring gear backlash 0.203 mm -
0.381 mm
(0.305 mm - 0.381 mm preferred)
0.008 in - 0.015 in
(0.012 in - 0.015 in preferred) Variation between teeth maximum backlash 0.102 mm (0.004 in)
Pinion flange runout 0.25 mm (0.010 in) T.I.R.
Torque Specifications Description Nm lb-
ft lb-
in Bolt retaining the differential pinion shaft to the differential case 30 22 —
Bolt retaining the driveshaft yoke to the pinion flange 112 83 —
Bolt retaining the differential housing cover to the differential housing 44 32 — Klj . 1 ba
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